Integral brush with no gaps between cleaning assembly and handle and manufacturing process thereof

ABSTRACT

An integral brush is formed by performing steps of tufts arrangement, tufts insertion into mold, mold turning and closing, and injection molding, thereby forming no gaps between cleaning assembly and handle. The cleaning assembly includes at least one cleaning unit each having a plurality of tufts integrally formed with one of a plurality of bases in the handle. The tufts are spaced apart and an upper portion of each tuft is shaped to form an uneven tip. The brush can increase a contact area between the cleaning assembly and an object so as to effectively clean the object.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to cleaning instrument and more particularly to an integrally formed brush with no gaps between a cleaning assembly and a handle. The invention also relates to a process of manufacturing the integrally formed brush.

2. Description of Related Art

There are a wide variety of brushes such as toothbrush, brush for cleaning face, and brush for cleaning purpose. Typically, a brush includes a handle and a cleaning assembly formed on a head of the handle.

Conventionally, brushes are secured to a handle by insertion. In detail, a plurality of tufts that include at least one bristle are bent. A hard member such as metal is attached to the bending portion. Next, the tufts and the hard member together are inserted into cavities in the handle. Finally, the tufts are secured to the handle.

However, a plurality of gaps may be formed between the tufts and the cavities. Thus, dirt may be left in the gaps. Further, liquid tends to store in the gaps and thus microorganisms may grow in the gaps. It is not hygienic. Further, the bent tufts may return to an inclined position after a period of time of use due to elasticity thereof. Thus, it is not durable.

Conventionally, a cleaning unit of a brush comprises a plurality of spaced tufts each adapted to provide a point contact with an object such as teeth, skin, or surface when it is rubbed against the object. Unfortunately, this cannot effectively clean dirt in the gaps of the object. The gaps may refer to, for example, the teeth, the gums, the gaps between the teeth, and the areas adjacent to the teeth and the gums. Further, tips of the tufts are flat, and section of the tufts of the cleaning unit is annular. All of these drawbacks hinder an effective cleaning of the dirt left in the gaps when using a brush to rub an object. Thus, the need for improvement still exists.

SUMMARY OF THE INVENTION

It is therefore one object of the invention to provide a brush having a cleaning assembly and a handle formed integrally by injection molding with no gaps between the cleaning assembly and the handle. This can prevent dirt and liquid from being left on the brush. Otherwise, microorganisms may grow on the brush. The brush of the invention is more hygienic than the conventional brush.

It is another object of the invention to provide an integral brush with no gaps between a cleaning assembly and a handle wherein the cleaning assembly comprises at least one cleaning unit each having a plurality of tufts integrally formed with a base. Each cleaning unit provides a multiple contact with an object similar to an area contact when it is rubbed against the object such as teeth, skin, or surface. Thus, it can totally clean gaps in the object. For example, the teeth, the gums, the gaps between the teeth, and the areas adjacent to the teeth and the gums.

It is still another object of the invention to provide an integral brush with no gaps between a cleaning assembly and a handle wherein the tufts are spaced apart and an upper portion of each tuft is shaped to form an uneven tip, thereby increasing a contact area between the cleaning assembly and an object so as to effectively clean the object.

For achieving above and other objects of the invention, there is provided an integral brush comprising a handle; and a cleaning assembly integrally formed with the handle with no gaps therebetween, the cleaning assembly including at least one cleaning unit each having a plurality of tufts integrally formed with one of a plurality of bases in the handle; wherein the tufts are spaced apart; and wherein an upper portion of each of the tufts is shaped to form an uneven tip.

In a preferred embodiment of the invention, the cleaning unit has a plurality of tufts having a conic portion adjacent to the tip.

In a preferred embodiment of the invention, the cleaning unit has a plurality of tufts having a polygonal section.

In a preferred embodiment of the invention, the polygonal section is a rhombic section.

In a preferred embodiment of the invention, the cleaning assembly includes a plurality of cleaning units.

In a preferred embodiment of the invention, the cleaning units are shaped to form an uneven top.

In a preferred embodiment of the invention, the cleaning assembly has a convex top.

The invention further provides a process of manufacturing an integral brush comprising the steps of tufts arrangement involving arranging a plurality of tufts as one of a plurality of cleaning units and fusing bases of the cleaning units to form a unitary member; tufts insertion into mold involving inserting heads of the cleaning units through a plurality of holes of a die, and activating a pushing device to push the cleaning units further into a plurality of holes of an upper mold with lower portions of the cleaning units disposed out of the upper mold; mold turning and closing involving turning the upper mold upside down to align with a lower mold so as to together form a cavity with a portion adjacent to the base of each of the cleaning units is disposed in the cavity; and injection molding involving forming a handle in the cavity and joining the portion adjacent to the base of each of the cleaning units and the handle by injection molding with no gaps formed between the handle and the portion adjacent to the base of each of the cleaning units.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention, as well as its many advantages, may be further understood by the following detailed description and drawings in which:

FIG. 1 is a side elevation of an integral brush with no gaps between cleaning assembly and handle according to a first preferred embodiment of the invention;

FIG. 2 is a top view of the integral brush with no gaps between cleaning assembly and handle in FIG. 1;

FIG. 3 is an enlarged view of the cleaning unit;

FIG. 4 is a sectional view taken along line 4-4 of FIG. 3;

FIG. 5 is a side elevation of an integral brush with no gaps between cleaning assembly and handle according to a second preferred embodiment of the invention;

FIG. 6 is a top view of the integral brush with no gaps between cleaning assembly and handle in FIG. 5;

FIG. 7 is a side elevation of an integral brush with no gaps between cleaning assembly and handle according to a third preferred embodiment of the invention;

FIG. 8 is a top view of the integral brush with no gaps between cleaning assembly and handle in FIG. 7;

FIG. 9 is a side elevation of an integral brush with no gaps between cleaning assembly and handle according to a fourth preferred embodiment of the invention;

FIG. 10 is a top view of the integral brush with no gaps between cleaning assembly and handle in FIG. 9;

FIG. 11 is a side elevation of an integral brush with no gaps between cleaning assembly and handle according to a fifth preferred embodiment of the invention;

FIG. 12 is a top view of the integral brush with no gaps between cleaning assembly and handle in FIG. 11;

FIG. 13 is a flow chart illustrating a process of manufacturing the integral brush with no gaps between cleaning assembly and handle according to the invention;

FIG. 14 schematically depicts the tufts insertion into mold step of FIG. 13; and

FIG. 15 schematically depicts the mold turning and closing and the injection molding steps of FIG. 14.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIGS. 1 to 4, an integral brush with no gaps between cleaning assembly and handle in accordance with a first preferred embodiment of the invention comprises a handle 10, and a cleaning assembly 20 integrally formed with the handle 10 with no gaps therebetween, the cleaning assembly 20 including at least one cleaning unit 21 each having a plurality of tufts 23 that include at least one bristle integrally formed with a base 22 in the handle 10. The tufts 23 are spaced apart. A portion of an upper portion 24 of the tuft 23 is shaped to form a tip 25 which is uneven. In the first preferred embodiment, a plurality of cleaning units 21 are provided and the cleaning units 21 are spaced apart.

As shown in FIG. 3, the cleaning unit 21 includes a plurality of tufts 23 each shaped to form a tip 25 at an end. The tips 25 form an uneven shape. Preferably, the cleaning unit 21 has a conic portion adjacent to the tip 25. In an oral cleaning operation, the tufts 23 can be easily inserted into gaps, for example, between teeth or between a tooth and gums, or an area between a tooth and gums so as to effectively remove plaque. Further, the spaced tufts 23 are in multiple contacts with the teeth so that a cleaning area on the teeth can be increased when the cleaning assembly 20 rubs the teeth. As a result, the invention can provide a cleaning effect to the teeth.

As shown in FIG. 4, the cleaning unit 21, including a plurality of tufts 23, has a polygonal section such as rhombus. A multiple point resistance is exerted on the cleaning units 21 having a rhombic section when the cleaning units 21 are inserted between the teeth and areas adjacent to the teeth. The multiple point resistance provide an about turbulence and shredding effect. As a result, plaque can be totally removed out of the teeth.

Referring to FIGS. 5 and 6, an integral brush with no gaps between cleaning assembly and handle in accordance with a second preferred embodiment of the invention is shown. The characteristics of the second preferred embodiment are substantially the same as that of the first preferred embodiment except the following: The tip 25 of the tufts 23 is flat.

Referring to FIGS. 7 and 8, an integral brush with no gaps between cleaning assembly and handle in accordance with a third preferred embodiment of the invention is shown. The characteristics of the third preferred embodiment are substantially the same as that of the first preferred embodiment except the following: The cleaning unit 21, including a plurality of tufts 23, has a circular section.

Referring to FIGS. 9 and 10, an integral brush with no gaps between cleaning assembly and handle in accordance with a fourth preferred embodiment of the invention is shown. The characteristics of the fourth preferred embodiment are substantially the same as that of the first preferred embodiment except the following: Only one cleaning unit 21 is provided by the cleaning assembly 20. The tufts 23 are closed arranged with almost no gaps among them. The cleaning assembly 20 has a convex top 26 and is appropriate for cleaning face.

Referring to FIGS. 11 and 12, an integral brush with no gaps between cleaning assembly and handle in accordance with a fifth preferred embodiment of the invention is shown. The characteristics of the fifth preferred embodiment are substantially the same as that of the fourth preferred embodiment except the following: Top 27 of the cleaning assembly 20 is flat.

Referring to FIGS. 13 to 15, a process of manufacturing integral brush with no gaps between cleaning assembly and handle in accordance with the invention is illustrated. The process comprises the following steps as detailed below. A tufts arrangement step involves arranging a plurality of tufts 23 as a cleaning unit 21 and fusing a base 22 with the cleaning unit 21 to form a unitary member. A tufts insertion into mold step involves inserting heads of a plurality of cleaning units 21 through a plurality of holes 31 of a die 30, and activating a pushing device (not shown) to push the cleaning units 21 further into a plurality of holes 41 of an upper mold 40 with lower portions of the cleaning units 21 disposed out of the upper mold 40. A mold turning and closing step involves turning the upper mold 40 upside down to align with a lower mold 42 so that they together form a cavity 43. A portion 28 adjacent to the base 22 of each cleaning unit 21 is disposed in the cavity 43. An injection molding step involves forming a handle 10 in the cavity 43 and joining the portion 28 adjacent to the base 22 and the handle 10 by injection molding wherein no gaps are formed between the portion 28 adjacent to the base 22 of each cleaning unit 21 and the handle 10.

It is envisaged by the invention that the integral brush with no gaps between cleaning assembly and handle has the following advantages in comparison with conventional brush: The cleaning assembly and the handle are formed integrally by injection molding and thus there is no gaps between the cleaning assembly and the handle. This can prevent dirt and liquid from being left on the brush. Otherwise, microorganisms may grow on the brush. The brush of the invention is more hygienic than the conventional brush. The cleaning assembly comprises at least one cleaning unit each having a plurality of tufts integrally formed with a base. Each cleaning unit provides a multiple contact with an object (i.e., similar to an area contact) when it is rubbed against the object (e.g., teeth, skin, or surface). Thus, it can totally clean gaps in the object. For example, these gaps exist in the teeth, the gums, the gaps between the teeth, and the areas adjacent to the teeth and the gums. Upper portions of the tufts are spaced apart with an uneven shape formed on its tops. The brush can increase a contact area between the cleaning assembly and an object so as to effectively clean the object.

Many changes and modifications in the above described embodiment of the invention can, of course, be carried out without departing from the scope thereof. Accordingly, to promote the progress in science and the useful arts, the invention is disclosed and is intended to be limited only by the scope of the appended claims. 

What is claimed is:
 1. An integral brush comprising: a handle; and a cleaning assembly integrally formed with the handle with no gaps therebetween, the cleaning assembly including at least one cleaning unit each having a plurality of tufts integrally formed with one of a plurality of bases in the handle; wherein the tufts are spaced apart; and wherein an upper portion of each of the tufts is shaped to form an uneven tip.
 2. The integral brush of claim 1, wherein the cleaning unit has a plurality of tufts having a conic portion adjacent to the tip.
 3. The integral brush of claim 1, wherein the cleaning unit has a plurality of tufts having a polygonal section.
 4. The integral brush of claim 3, wherein the polygonal section is a rhombic section.
 5. The integral brush of claim 1, wherein the cleaning assembly includes a plurality of cleaning units.
 6. The integral brush of claim 5, wherein the cleaning units are shaped to form an uneven top.
 7. The integral brush of claim 1, wherein the cleaning assembly has a convex top.
 8. A process of manufacturing an integral brush of claim 1, comprising the steps of: tufts arrangement involving arranging a plurality of tufts as one of a plurality of cleaning units and fusing bases of the cleaning units to form a unitary member; tufts insertion into mold involving inserting heads of the cleaning units through a plurality of holes of a die, and activating a pushing device to push the cleaning units further into a plurality of holes of an upper mold with lower portions of the cleaning units disposed out of the upper mold; mold turning and closing involving turning the upper mold upside down to align with a lower mold so as to together form a cavity with a portion adjacent to the base of each of the cleaning units is disposed in the cavity; and injection molding involving forming a handle in the cavity and joining the portion adjacent to the base of each of the cleaning units and the handle by injection molding with no gaps formed between the handle and the portion adjacent to the base of each of the cleaning units. 